1. Opportunities for development of a “Sugarcane” Industry
Sugarcane as an Energy crop
Harold Davis and Paul Hough
April 2006

2. Prevailing Conditions
Caribbean Sugar Industries characterised by high cost
Old Technologies, small factories and relatively high wages
Traditionally dependent on preferential prices for raw sugar
Significant price reductions from EU, the main preferential market

3. Raw sugar production can no longer sustain an economically industry
Future of Sugarcane in the Caribbean
Raw sugar production can no longer
sustain an economically industry
Exploit the total biomass of this unique crop
Electricity generation and ethanol
will become increasingly important
outputs from sugarcane production

4. Features of Guyana Industry
With a production capacity of 320,000 tonnes at unit cost 18¢ per pound sugar, the Guyana Sugar Industry is probably the most competitive in the SAC group
This Industry is also challenged by the new market prospects arising from the EU cuts
Guysuco has developed a long term strategic plan for cost reduction based on expansion and improved efficiency.

5. Guysuco-Strategy-1998 Expand Industry & Diversify Product Base
Construct new 8400 tcd mill – to produce refined sugar with co-generation of 10MW electricity
Possible joint venture potable alcohol distillery at new factory
Increase yields and reduce production costs on remainder of industry
By 2010 sugar output 450,000 + tonnes

6. Strategy Implementation
Strategy revolves around reduction in production cost to 12¢ per pound sugar
Cost of operations largely dependent on labour intensive cane cultivation and harvesting
Progress made with layout modification and reducing operating costs by increased mechanisation of agronomic practices
Collaborating with WICSCBS in variety evaluation for energy and other potential uses
24 MPC varieties being propagated

7. Characteristics – DB 9633 DB 9633 DB 7869 120 tc/ha- Pl+2R
Pol% cane – 13% - 14%
Pol% cane ~ 12%
Fibre% cane – 16%-18 %
Fibre% cane – 14% - 16%

8. Skeldon Project Milestones
1999-Commence land development for new sugarcane project at Skeldon
2001-Booker-Tate appointed Project Manger
2002 -World Bank clearance for financing
2003- EIA and Env Permit approved
2004 – Agreement for cogeneration component with Power Company and Financing bank
2005- Env Management Plan approved
2005- Factory Contracts signed
2006- Commence Factory Construction

9. Features of Skeldon Project
Net sugarcane cultivation to increase from 4270ha – estate and 310ha –farmers to 8700 ha – estate and 4250 ha farmers
Factory capacity 8400 tonnes cane per day
Crop duration 27 weeks net!
At steady state design capacity for 1,170,000 tonnes cane and and production of 110,000 VHP sugar

10. Features of Skeldon Project contd.
First diffuser in SAC industries
Rum distillery under consideration as joint venture with Angostura Ltd.
Factory will export 10MW to grid under firm power agreement
Feasibility study and negotiations for refinery as joint regional venture in progress
Refinery may be sited at alternative Berbice factory given Skeldon’s commitment to grid

11. Cogeneration Plant Equipment
Two 125 tons/hr Boilers operating at 53 Bar and 485ºC
Extraction/Condensing T/A output 15MW
Back pressure T/A output 15MW
Three Diesel Alternators combined output 10MW
Heavy Fuel Oil for Diesel Alternators

12. Plant Operating Features
Sugar factory power kW
Process steam kg/hr
Cogen plant load kW
Cogen plant steam kg/hr
Bagasse 34%cane t
Bagasse consumed in crop t
Bagasse storage t

13. Skeldon Cogeneration operation
Projected 10MWexport power from bagasse fired boilers for 37 weeks to 40 weeks including 10 weeks out of crop from stored bagasse
Projected 8MW export power from Diesel alternators when bagasse stock exhausted
Supplementing stored bagasse with imports from Albion will extend out of crop generation period
6 week window of opportunity for fuel/mpc cane to supplement fuel supply to plant after juice directed to distillery.

14. Energy Content of Sugar-cane (Guyana)
1 Tonne Cane
110 kg sugar MJ
170 kg stalk fibre MJ
140 kg top fibre(trash) MJ
Tot MJ
1 tonne cane approx. equivalent to 1 barrel of oil
(ex Dr. M. Regis Leal -2003)

15. Fuel Potential of Sugarcane
Potential for leaves and tops to contribute to boiler fuel
These should be removed prior to process for efficient extraction of sugars and fermentables
Cellulosic materials associated with alkali and alkaline earth ions which can induce slag formation and reduce boiler efficiency
Bagasse has advantage over other cellulosic fuels because extraction and washing removes significant amounts of alkalis and alkaline earths

16. Meeting electrical requirements with back-pressure turbogenerators (at constant steam demand)
mst
Pel
import power
export power
1,7
1,6
30 bar, 400°C
1,5
23 bar, 350°C
1,4
40 bar, 450°C
1,3
1,2
60 bar, 500°C
1,1
Specific electricity demand (kWh/t beet or cane)
Specific steam demand (% on beet or cane)
Live steam conditions at Turbine inlet
1,0
85 bar, 525°C
0,9
0,8
0,7
0,6
0,5
0,4 % 30 40 50 60 70 80 90
100
110
120
130
140
150
160
170
Electrical self-sufficiency (100 %) and generation of excess power for export (above 100 %)

17. Power Characteristics –Integrated Factory with Annexed Distillery
Front end consumption kwh/t cane
Process consumption kwh/t cane
Pot bar 444°C kwh/t cane
Pot 82 bar 525°C kwh/t cane
Distillery consumption ~ kwh/t cane

18. Cogen Potential 4800TCD Case Study
Cane Production -``````926100t
5MW Plant kwh/t cane
10 MW Plant kwh/t cane
12 MW Plant kwh/t cane
15 MW Plant kwh/t cane
Implies a 15 MW facility can probably be supported

19. Possible Sugar & Ethanol Production - Guyana Pol% cane 11%, Purity 81%
Standard Process – EtOH from final molasses only- sugar – 9% cane, EtOH – 10l/t cane
A strike only – sugar – 6.1% on cane, EtOH – 25l/t cane
A & B strike – sugar – 7.6% on cane, EtOH- 17l/t cane
Ethanol only – 60l/t cane to 66l/t cane

20. Ethanol Research
4800 TCD factory could produce tonnes sugar and 11.3 M Liters of Ethanol
11.3 M Liters ethanol will permit 10% substitution in Gasolene
Ethanol production from factory generated molasses and fuel cane indicated to cost between 12¢ to 14¢ per Liter
Import price of Gasolene in ¢ per Liter
Gasolene spot price reached 37¢ per Liter in June 2005

21. Production 4800 TCD Case Study
Sugar t
Ethanol M liters
(a) Cogen 5MW - 42GWh
(b) Cogen 12 MW GWh

22. Study Conclusions
Integrated production of sugar, ethanol and energy as electricity offered best economic potential from a factory of 4800 TCD capacity.
Fuel ethanol rapidly growing market possibilities including import substitution by gasolene blends and export
High fibre “energy cane” has potential role in extending crop to periods of weather disruption for power and ethanol production

23. Commercial Ethanol prospects
Full feasibility to be conducted for a 12M liter fuel ethanol distillery from non contract molasses
Strong interest expressed by investors in a 130M liter fuel ethanol project from sugarcane on green field site
This project could support a 30MW cogeneration facility

24. Planned Future Projects
Guysuco future plans include expansions of Enmore, Blairmont and Albion factories to capacities of 4400 to 5100 tcd.
Enmore is planned to be the focus of branded packaged sugar. Albion is being considered as an alternative site for a refinery
The expanded Enmore and Albion factories would have cogeneration capabilities with minimum exports of 7MW

25. Next Steps Feasibility of Proposed factory expansions
Full Feasibility Study of Integrated Production Model inclusive of ethanol production
Support for national commitment to renewable energy with recognition of the role of sugarcane

26. THANK YOU FOR YOUR ATTENTION